molex 63811-3300 User manual

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 1 of 11
Revision: D Revision Date: 10-04-10
Application Tooling
Specification Sheet
Tool Kit
Order No. 63811-3370
Hand Crimp Tool
Order No. 63811-3300
FEATURES
A full cycle ratcheting hand tool ensures complete crimps
Ergonomically designed soft handles
Precisely designed crimping profiles with simple contact positioning
Easy handling due to outstanding force ratio
Tool kits are easily installed into the Hand Crimp Tool or the 63816-0300 Power Crimp Head which is installed
into the 63816-0200 (110 V) or the 63816-0250 (220 V) Battery Powered Tool.
Many different Tool kits can be used with a single Battery Powered Tool.
This tool is IPC/WHMA-A-620 Class 2 and RoHS compliant.
SCOPE
Products: .1.57mm (.062") Diameter, Standard .062" Pin and Socket Crimp Terminal, 18-24 AWG.
KK® Crimp Terminal, Flat Blade Crimp Terminal, and
4.80mm (.189") Pitch Crimp Terminal, 18-24 AWG.
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
1560
02-06-2103
02-06-6119
02-06-2101
02-06-6118
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
02-06-6102
04-01-0807
02-06-6100
04-01-0805
02-06-6103
39-00-0327
02-06-6101
39-00-0328
02-06-6104
39-00-0330
02-06-6105
39-00-0329
02-06-6112
02-06-6116
39-00-0378
1561
02-06-1103
04-01-0808
02-06-1101
02-06-5108
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
02-06-5102
39-00-0331
02-06-1118
04-01-0806
02-06-5103
39-00-0334
02-06-5100
39-00-0279
02-06-5104
02-06-5101
39-00-0333
02-06-5109
02-06-5105
1786
02-06-2202
02-06-6206
02-06-2201
02-06-6205
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
02-06-6202
02-06-6212
02-06-6201
02-06-6211
1787
02-06-1202
02-06-5202
02-06-1201
02-06-5201
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
02-06-3201
02-06-5206
02-06-3200
02-06-5205
1799
08-30-0110
08-34-0110
08-30-0109
08-34-0109
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
08-34-0106
08-35-0106
08-34-0105
08-35-0105
08-34-0108
08-34-0107
1943
05-06-0201
05-06-0206
05-06-0200
05-16-0200
18-24
0.82-0.20
1.52-2.79
.060-.110
2.41-3.04
.095-.120
05-06-0204
05-06-0205
05-16-0201
05-06-0203
05-06-0211
4529
02-06-1105
02-06-5208
02-06-1104
02-06-5207
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
02-06-5118
02-06-5218
02-06-5117
TYPE 2C

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 2 of 11
Revision: D Revision Date: 10-04-10
INSULATION
CRIMP
BRUSH
STRIP
LENGTH
BELL MOUTH
CRIMP HEIGHT
BEND
DOWN
BEND UP
ROLLING
CONDUCTOR
CRIMP
TWISTING
Terminal
Series No.
Terminal Order No.
Wire Size
Insulation Diameter
Strip Length
Loose Piece
Reel
AWG
mm²
mm
In.
mm
In.
5005
08-70-0042
39-00-0014
08-70-0001
39-00-0013
18-24
0.82-0.20
1.30-3.00
.051-.118
2.30-2.95
.090-.116
08-70-1012
08-70-1011
5006
08-70-0043
39-00-0016
08-70-0002
39-00-0015
18-24
0.82-0.20
1.30-3.00
.051-.118
2.30-2.95
.090-.116
08-70-1014
08-70-1013
6770
02-06-5142
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
6772
02-06-6140
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
7291
02-06-1139
18-24
0.82-0.20
1.52-3.05
.060-.120
2.41-3.04
.095-.120
8662
16-02-0050
16-02-0049
18-24
0.82-0.20
1.52-2.79
.060-.110
2.41-3.04
.095-.120
8960
16-02-0053
18-24
0.82-0.20
1.52-2.79
.060-.110
2.41-3.04
.095-.120
Follow the Cut-Off Tab specifications on Applicator specification sheets.
See Conditions on page 2.
DEFINITION OF TERMS
The above terminal drawing is a generic terminal representation. It is not an image of a terminal listed in the
scope.
CONDITIONS:
After crimping, the conductor profiles should measure the following (see notes below).
Terminal
Series No.
Hand Tool
Locator
Wire Size
Conductor Crimp
Height (REF)
Conductor
Crimp Width (Ref)
Pull Force
Minimum
Profile
AWG
mm2
mm
In.
mm
In.
N
Lb.
A
B
1560
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
89.0
20.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
1561
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
89.0
20.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
1786
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
89.0
20.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 3 of 11
Revision: D Revision Date: 10-04-10
Terminal
Series No.
Hand Tool
Locator
Wire Size
Conductor Crimp
Height (REF)
Conductor
Crimp Width (Ref)
Pull Force
Minimum
Profile
AWG
mm2
mm
In.
mm
In.
N
Lb.
A
B
1787
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
89.0
20.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
1799
2
18
0.82
1.02-1.12
.040-.044
1.95
.077
111.3
25.00
X
2
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
2
22
0.32
0.87-0.97
.034-.038
1.95
.077
53.4
12.00
X
2
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
1943
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
111.3
25.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
53.4
12.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
4529
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
89.0
20.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
5005
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
98.0
22.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
53.4
12.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
5006
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
98.0
22.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
53.4
12.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
6770
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
89.0
20.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
6772
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
89.0
20.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
7291
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
89.0
20.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
35.6
8.00
X
8662
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
111.3
25.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
31.4
7.00
X
8960
1
18
0.82
1.02-1.12
.040-.044
1.95
.077
111.3
25.00
X
1
20
0.52
0.87-0.97
.034-.038
1.95
.077
66.8
15.00
X
1
22
0.32
0.87-0.97
.034-.038
1.95
.077
44.5
10.00
X
1
24
0.20
0.87-0.97
.034-.038
1.95
.077
31.4
7.00
X
Tool Qualification Notes:
1. Pull Force should be measured with no influence from the insulation crimp.
2. The above specifications are guidelines to an optimum crimp.

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 4 of 11
Revision: D Revision Date: 10-04-10
SWING
LOCATOR
OPEN
PRESS DOWN
ON THE BRASS
PIVOT SHAFT
LIFT UP ON
THE LOCATOR
Figure 2
ANVILS
POWER
CRIMP
HEAD
Figure 1
PUNCHES
M4 X 10 LONG
BHCS
M4 X 18 LONG
BHCS
Note:
A crimp height chart is provided with this manual as Reference Only. Due to the wide range of wires, strands,
insulation diameters, and durometers, actual crimp height measurements may very slightly. An occasional,
destructive, pull force test should be preformed to check hand tool crimp. Pull Force value Must exceed the
Minimum pull force specifications listed on pages 2 and 3.
CAUTION: Install only Molex terminals listed above with this tool. Do not crimp hardened objects as damage
can occur to the tool or die.
INSTALLATION
To install the Tool Kit into the Power Crimp Head follow the steps below:
Anvils and Punches Installation
1. Insert the Anvils into the bottom slots of the nest. Install the M4 x 10 long BHCS and tighten in place.
2. Insert the Punches into the top slots of the nest. Install the M4 x 18 long BHCS and tighten in place. See
Figure 1.
Locator Installation and Removal
Follow the steps below to install or replace the locator. See Figure 2.
To install the locator
1. Position the locator with the hole over the brass pivot shaft and
snap it into place.
To remove the locator
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the hand tool.
3. Firmly press down on the brass pivot shaft with your thumb, while
pulling the locator up. Slip the locator off the top of the brass pivot shaft.
Figure 3
LOCATOR
JAWS OPEN

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 5 of 11
Revision: D Revision Date: 10-04-10
OPERATION
Open the tool by squeezing the handles together, at the end of the closing stroke, the ratchet mechanism will
release the handles, and
the hand tool will spring
open.
Crimping Terminals
1. Select the desired
terminal listed in the
preceding charts.
Make sure that the
proper locator is
mounted on the tool.
2. Swing the terminal
locator away from the
crimp tool shown in
Figure 4. Some
terminals with large insulation grips may interfere with the
crimp tooling when swinging the locator into position. The
terminal must then be loaded into the locator in the
closed/crimp position.
3. When using 63811-3275 (Locator No. 1), press down on the
wire stop on the locator as shown in Figure 4. Insert the
proper terminal into the proper nest opening. Make sure when
choosing the nest opening, it will correspond with the A or B
profile on the hand tool.
4. Return the locator to its original position.
5. Insert the proper wire over the terminal. Gently touch the wire
stop with the end of the wire. See Figure 5.
6. Compress the terminal by squeezing the tool handles until the
ratchet mechanism cycle has been completed. Release
handles to open the jaws.
7. Remove the crimp terminal from the terminal locator by
pressing down on the wire stop and gently pulling on the wire.
The terminal locator can by in either position
8. Visually inspect the crimped terminal for proper crimp location
and crimp height.
Note: The tamper proof ratchet action will not release the tool until it has been fully closed.
For the Battery Power Tool:
1. Cycle the Battery Power Tool to crimp the terminal to the wire.
2. Remove the crimped terminal from the terminal locator by pressing down on the wire stop and gently pulling on
the wire. The terminal locator can be in either position.
3. Visually inspect the crimped terminal for proper crimp location.
TERMINAL
PUSH HERE TO
OPEN WIRE STOP
SWING OPEN
LOCATOR
LOCATOR
TERMINAL
IN PLACE
Figure 4
LOCATOR
IN PLACE
WIRE STOP
TERMINAL
WIRE
WIRE STOP
WIRE
AGAINST STOP
Figure 5

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 6 of 11
Revision: D Revision Date: 10-04-10
TERMINAL FLUSH WITH
INSULATION TOOLING
INSULATION TOOLING
Figure 5A
Crimping Terminals without a Locator
1. With the hand tool in the open position, select the proper profile.
2. Position the terminal in the proper profile; partially close the hand
tool until the terminal is held in place. The terminal should be
positioned so that the front of the insulation grips is flush with the
front face of the insulation tooling. See Figure 5A.
3. Gently slip the wire into the terminal, and then position the
insulation and stripped strands into the terminal insulation and
conductor grips. Note: No wire stop is provided. If the wire will not
fit into the partially closed tool, due to large insulation diameter, the
terminal and wire must then be placed in the open tool. Applying
slight downward pressure on the wire may help hold the terminal in place while crimping.
4. Compress the terminal by squeezing the tool handles until the ratchet mechanism cycle has been completed.
Release handles to open the jaws.
Locator Change Over
Two styles of locators are provided with the crimp hand
tool 63811-3300. They are locator no. 1 (63811-3375),
which is black and locator no.2 (63811-3376), which is
gray. Make sure the desired style of locator is installed
for the proper terminal and wire. Follow the steps
below to change the locators.
1. Open the crimp hand tool.
2. Swing the existing locator open and away from the
hand tool.
3. Firmly press down on the brass pivot shaft with
your thumb, while pulling the locator up. Slip the
locator off the top of the brass pivot shaft. See
Figure 6.
4. Replace it with the desired locator by putting over the brass pivot shaft and snapping it into place.
Maintenance
It is recommended that each operator of the tool be made aware of, and responsible for, the following maintenance
steps:
1. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint free cloth.
2. Do not use any abrasive materials that could damage the tool.
3. Make certain all pins; pivot points and bearing surfaces are protected with a thin coat of high quality machine
oil. Do not oil excessively. The tool was engineered for durability but like any fine piece of equipment it needs
cleaning and lubrication for a maximum service life of trouble free crimping. Use a 30 weight automotive (light)
oil used at the oil points, every 5,000 crimps or 3 months, shown in Figure 7A or 7B will significantly enhance
the tool life.
4. Wipe excess oil from hand tool, particularly from crimping area. Oil transferred from the crimping area onto
certain terminations may affect the electrical characteristics of an application.
SWING
LOCATOR
OPEN
PRESS DOWN ON
BRASS PIVOT SHAFT
LIFT UP
LOCATOR
JAWS
OPEN
Figure 6

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 7 of 11
Revision: D Revision Date: 10-04-10
5. When tool is not in use, keep the handles
closed to prevent objects from becoming
lodged in the crimping dies, and store the
tool in a clean, dry area.
Miscrimps or Jams
Should this tool ever become stuck or jammed
in a partially closed position, Do Not force the
handles open or closed. The tool will open
easily by pressing the ratchet release lever.
See Figure 8.
How to Adjust Tool Preload (See
Figure 8)
This hand tool is factory preset to 25-45 LBS. preload. It may be necessary over the life of the tool to adjust tool
handle preload force. Listed below are the steps required to adjust the crimping force of the hand tool to obtain
proper crimp conditions:
1. Remove or fold back the handle grip from the
handle to expose the eccentric axle and
setting wheel.
2. Remove the locking screw with a 2mm hex
wrench. The wrench set (63810-0101), is not
supplied. It is sold separately from the hand
tool.
3. Turn the eccentric axle and setting wheel with
the wrench or pliers Counter-clockwise (CCW)
to increase handle force.
4. Replace the locking screw, aligning the
nearest notch in the setting wheel to locking
screw.
5. Replace the handle grip.
6. Check the crimp specifications or conduct a
pull test after tool handle preload force is
adjusted.
Warranty
This tool is for electrical terminal crimping purposes only. This tool is made of the best quality materials. All vital
components are long life tested. All tools are warranted to be free of manufacturing defects for a period of 30
days. Should such a defect occur, we will repair or exchange the tool free of charge. This repair or exchange will
not be applicable to altered, misused, or damaged tools. This tool is designed for hand use only. Any clamping,
fixturing, or use of handle extensions voids this warranty.
CAUTION: Molex crimp specifications are valid only when used with Molex terminals and tooling.
RATCHET
RELEASE LEVER
Figure 8
HANDLE
GRIP
REMOVED
ECCENTRIC AXLE
HANDLE
GRIP
LOCKING
SCREW
WRENCH SET
(SOLD
SEPERATELY)
PRELOAD
CHECK POINT
25.4MM
SETTING WHEEL
Figure 7B
LUBRICATION
POINTS
(BOTH SIDES)
LIGHT OIL
(EVERY MONTH
OR
5,000 CRIMPS)
Figure 7A

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 8 of 11
Revision: D Revision Date: 10-04-10
CAUTIONS
1. Manually powered hand tools are intended for low volume or field repair. This tool is NOT intended for
production use. Repetitive use of this tool should be avoided.
2. Insulated rubber handles are not protection against electrical shock.
3. Wear eye protection at all times.
4. Use only the Molex terminals specified for crimping with this tool.
Certification
Molex does not certify or re-certify commercial grade hand tools but rather supplies the following guidelines for
customers to re-certify hand tools.
This tool is qualified to pull force only. To re-certify, crimp a terminal to a wire, which has been stripped
12.7mm (1/2”) long, so there is no crimping of the insulation. Pull the terminal and wire at a rate no faster than
25mm (1.00”) per minute. See the Molex web site for the Quality Crimp Handbook for more information on pull
testing.
If the tool does not meet minimum pull force values, handle preload should be increased and the pull test
rerun, (See How To Adjust Preload).
When the hand tool is no longer capable of achieving minimum pull force, it should be taken out of service and
replaced.

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 9 of 11
Revision: D Revision Date: 10-04-10
The chart below shows all applications for this Tool Kit.
Tool Kit
Order No.
Tool
Order no.
Tool
Description
Power Head
Order No.
Adapter
Description
Figure
No.
63811-3370
63810-0100
Hand Crimp Frame (Short)
N/A
N/A
9
63810-0400
Hand Crimp Frame (Long)
N/A
N/A
9
63816-0200
Battery Power Tool (110 V)
63816-0300
Power Crimp Head
10
63816-0250
Battery Power Tool (220 V)
63816-0300
Power Crimp Head
10
Applications for the Tool Kit
Hand Crimp Tool
Battery Powered Tool
Figure 9
Figure 10
WARNING: NEVER operate service, install tool kits, or adjust the Power Crimp Head without proper
instruction and without first reading and understanding the instructions in the proper Manual or
Specification Sheet. See Chart above for the correct Manual or Specification Sheet.
WARNING: NEVER install tooling or service this tool while it is into any power source. Make sure the
power is turned off.
CAUTION: Keep fingers away from the crimping area when operating this tool. It may cause severe injury.
CAUTION: Wear safety glasses when operating or serving this tool.
POWER
CRIMP
HEAD
LOCKING PINS
BATTERY
POWERED
TOOL
TOOLING KIT
HAND CRIMP
FRAME LONG
AND SHORT
TOOLING
KIT

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 10 of 11
Revision: D Revision Date: 10-04-10
RATCHET
RELEASE SCREW
Figure 11
1
3
M4 X 6mm
LONG BHCS
M4 X 12mm
LONG BHCS
5
7
WITH TOOL KIT
LOCATOR ONLY
M4 X 12mm
LONG BHCS
4
4
2
5
6
5
WITH TOOL KIT
LOCATOR ONLY
HAND TOOL PARTS LIST
Item Number
Order Number
Description
Quantity
1
63810-0100
Hand Crimp Frame (Short)
1
2
63810-0101
Wrench Set (Not included)
0
3
63810-0102
Locator Base
1
4
63810-0103
Repair Kit (Not included)
0
5
63811-3370
Tool Kit with Locator
1
6
63811-3375
Locator #1-Black
1
7
63811-3376
Locator #2-Gray
1

Tool Kit for 18-24 AWG Crimp Terminals
Doc No: ATS-6381133HM Release Date: 11-19-03 UNCONTROLLED COPY Page 11 of 11
Revision: D Revision Date: 10-04-10
Figure 12
1
2
2
M4 by 8 Long
BHCS
M4 by 18 Long
BHCS
M4 by 10 Long
BHCS
1
POWER HEAD PARTS LIST
Item
Order No
Engineering No.
Description
Quantity
1
63816-0300
63816-0300
Power Crimp Head
1
2
63811-3370
63811-3370
Tool Kit
1
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